Dewatering in Nigerian Mineral Mines

Dry Mines. Safe Workers. More Output. The Dewatering Advantage in Nigeria’s Mineral Mining Made Smarter with Cosmos Dewatering Solutions in Nigeria.

Overcoming Subterranean Water Challenges

The Problem:

For the past four months, water has been clogging a 1.8km operational zone in Nigerian mines, with depths reaching up to 60 meters. This has caused severe flooding and seepage, blocking mining operations. Standard pumping methods have proven ineffective, requiring customized pumps to address water volume, depth, and seepage challenges.

Impact:

Water accumulation led to up to a 45% reduction in mining output due to downtime for dewatering and the inability to operate equipment in flooded areas. Mining machinery, conveyor systems, and electrical equipment were damaged by prolonged exposure to water, leading to costly repairs and replacements. Given these estimates, the total financial loss from seepage-related issues at the mine within 4 months was around 30 million US$. This is based on the combined costs of lost productivity, equipment maintenance, safety measures, and downtime.

Pumps Used:

3 Autoprime Pumps: CAP250HH

Objectives:

Objectives

Efficient Water Removal

Objectives

Minimize Downtime and Improve Operational Efficiency

Objectives

Adaptation to Harsh Mining Environments:

Objectives

Energy Efficiency and Cost-Effectiveness

Solution Implemented

We provided a tailored solution for mines to address severe water clogging, and also, due to the severe condition, there was seepage, which made the dewatering task more challenging. For this challenging task, our team did the site assessment and developed a tailored 3 giant CAP250HH (600HP) dewatering pump, designed for high-performance dewatering in challenging conditions as the RPM required was much higher than usual. The modifications we used made effective water management and reduced downtime, ultimately enhancing mining productivity.

Results

  • Efficient Water Removal: 3 CAP250HH (600HP) pumps efficiently removed large volumes of water, maintaining manageable water levels and preventing flooding in the mine.
  • Reliable Performance: High RPM was rectified through design improvements, ensuring consistent operation and preventing valve issues.
  • Reduced Downtime: Continuous dewatering minimized operational interruptions, allowing us to maintain high productivity levels despite challenging conditions.
  • Cost Savings: The high efficiency and durability of the pumps reduced maintenance costs and energy consumption, providing a cost-effective long-term solution for the mine.

Project Outcomes and Strategic Insights

Long-term Benefits:

Increased Operational Efficiency:
Increased Operational Efficiency:

The continuous, reliable performance of the dewatering pumps ensured smoother mining operations, reducing downtime and optimizing resource extraction.

Cost Efficiency:
Cost Efficiency:

With the high power efficiency of the pumps, coupled with reduced maintenance requirements, long-term energy and repair costs were significantly lowered.

Conclusion:

In conclusion, we successfully addressed water flooding and seepage challenges at the mines by providing 3 high-performance CAP250HH (600HP) pumps. The solution improved operational efficiency, reduced downtime, and enhanced safety, delivering significant long-term cost savings and ensuring sustained productivity for the mine.

Future Recommendations:

Future recommendations include regularly upgrading pump systems to incorporate emerging technologies for enhanced efficiency, further optimizing the NRV design to handle higher RPMs, and conducting annual maintenance reviews. Additionally, expanding the monitoring system for real-time performance data and exploring sustainable energy solutions could improve long-term operational sustainability and cost savings.